air filter YAMAHA XVS1100A 2001 Owners Manual

DESCRIPTION
2-2
2
Right view (XVS1100)9. Engine oil filter element (page 6-7)
10. Battery (page 6-26)
11. Main fuse (page 6-28)
12. Main switch/steering lock (page 3-1)
13. Air filter element (page 6-11)
14. Brake pedal (page 3-7)
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DESCRIPTION
2-4
2
Right view (XVS1100A)9. Engine oil filter element (page 6-7)
10. Battery (page 6-26)
11. Main fuse (page 6-28)
12. Main switch/steering lock (page 3-1)
13. Air filter element (page 6-11)
14. Brake pedal (page 3-7)
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Removing and installing the panel ....................... 6-5
Checking the spark plugs .................................... 6-6
Engine oil and oil filter element ............................ 6-7
Final gear oil ........................................................ 6-9
Cleaning the air filter element ............................ 6-11
Adjusting the carburetors ................................... 6-12
Adjusting the engine idling speed ...................... 6-12
Adjusting the throttle cable free play .................. 6-13
Adjusting the valve clearance ............................ 6-13
Tires ................................................................... 6-13
Spoke wheels .................................................... 6-16
Adjusting the clutch lever free play .................... 6-17
Adjusting the brake lever free play ..................... 6-17
Adjusting the brake pedal position ..................... 6-19
Adjusting the rear brake light switch .................. 6-19
Checking the front and rear brake pads ............. 6-20
Checking the brake fluid level ............................ 6-21Changing the brake fluid ................................... 6-22
Checking and lubricating the cables ................. 6-22
Checking and lubricating the throttle grip
and cable ........................................................ 6-22
Checking and lubricating the brake and
shift pedals ...................................................... 6-23
Checking and lubricating the brake and
clutch levers .................................................... 6-23
Checking and lubricating the sidestand ............ 6-24
Checking the front fork ...................................... 6-24
Checking the steering ....................................... 6-25
Checking the wheel bearings ............................ 6-25
Battery ............................................................... 6-26
Replacing the fuses .......................................... 6-28
Replacing the headlight bulb ............................. 6-30
Replacing a turn signal light bulb or
the tail/brake light bulb .................................... 6-31
Troubleshooting ................................................. 6-32
Troubleshooting chart ........................................ 6-33
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-02ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.ÖÖÖÖ
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
7*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
8*Rear brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
9
*Brake hoses• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
10*Wheels• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.ÖÖÖÖ
11*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
12*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
13*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
14*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
15*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
16 Sidestand• Check operation.
• Lubricate.ÖÖÖÖ Ö
17*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
18*Front fork• Check operation and for oil leakage.ÖÖÖÖ
19*Rear shock absorber
assembly• Check operation and shock absorber for oil leakage.ÖÖÖÖ
• Lubricate the pivoting points with molybdenum disulfide
grease.ÖÖ
20*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
21 Engine oil• Change.ÖÖÖÖÖ Ö
22 Engine oil filter element•Replace.ÖÖÖ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
EAU03541
NOTE:_l
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l
Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
_23 Final gear oil• Check oil level and vehicle for oil leakage.ÖÖ Ö
• Change.ÖÖÖ
24
*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
25 Moving parts and cables• Lubricate.ÖÖÖÖ Ö
26*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´ 1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-7
6To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @4. Install the spark plug cap.
5. Place the spark plug cover in the
original position.
EAU01712
Engine oil and oil filter
element The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter ele-
ment replaced at the intervals specified
in the periodic maintenance and lubri-
cation chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. @2. Start the engine, warm it up for
several minutes, and then turn it
off.
a. Spark plug gapSpark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
20 Nm (2.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 3. Wait a few minutes until the oil set-
tles, and then check the oil level
through the check window located
at the bottom-left side of the crank-
case.
NOTE:@ The engine oil should be between the
minimum and maximum level marks.@4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.To change the engine oil without oil
filter element replacement
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.4. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
5. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
1. Engine oil filler cap
1. Engine oil drain boltTightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
EC000072
CAUTION:@ l
In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives
with the oil or use oils of a
higher grade than “CD”. In ad-
dition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
l
Make sure that no foreign mate-
rial enters the crankcase.
@
6. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:@ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. @
EC000067
CAUTION:@ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. @7. Turn the engine off, and then
check the oil level and correct it if
necessary.NOTE:@ Have a Yamaha dealer replace the oil
filter element when necessary. @
EAU02943*
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the final gear oil level must be
checked and the oil changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
EW000066
WARNING
@ l
Make sure that no foreign mate-
rial enters the final gear case.
l
Make sure that no oil gets on
the tire or wheel.
@
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
3.0 L
With oil filter element
replacement:
3.1 L
Total amount (dry engine):
3.6 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
EAU03195*
Cleaning the air filter element The air filter element should be cleaned
as follows at the intervals specified in
the periodic maintenance and lubrica-
tion chart. Clean the air filter element
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the air filter case cover by
removing the screws.
2. Pull the air filter element out.3. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.4. Insert the air filter element into the
air filter case as shown.
EC000082*
CAUTION:@ l
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
l
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
pistons and/or cylinders may
become excessively worn.
@5. Install the air filter case cover by
installing the screws.
1. Air filter case cover
2. Screw (´ 3)
1. Air filter element
2. Projection
3. Slot
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